Method for producing polycrystalline alumina abrasive grains

Abstract

A method for producing the polycrystalline alumina abrasive grains at a low cost, and a grindstone using the polycrystalline alumina abrasive grains. The production method includes a step of obtaining a liquid mixture of pseudo-boehmite, predetermined silica, and water; a step of adding a deflocculant to the liquid mixture to obtain a sol; a step of adding alumina seeds to the sol to obtain a seed-containing sol; a step of drying the seed-containing sol, crushing a residual content, and then performing calcination at 550° C. or more and less than 1,200° C.; and a step of performing firing at 1,200° C. to 1,500° C. provides the polycrystalline alumina abrasive grains including an alumina content of 95.0% by mass or more and a silica content of 0.05 to 3.30% by mass, with a grain size of 0.100 to 0.400 um, and a Vickers hardness of 21.00 or more.

1 . A method for producing polycrystalline alumina abrasive grains, the method comprising:
 a step of obtaining a liquid mixture of pseudo-boehmite, silica having an average particle diameter of 100 nm or less at 0.01 parts by mass or more and less than 3.0 parts by mass with respect to 100 parts by mass of a solid content of the pseudo-boehmite, and water of 400 to 630 parts by mass with respect to 100 parts by mass of the solid content of the pseudo-boehmite;   a step of adding a deflocculant to the liquid mixture to obtain a sol;   a step of adding alumina seeds having a median diameter (D50) of 700 nm or less at 0.01 to 5.0 parts by mass with respect to 100 parts by mass of the solid content of the pseudo-boehmite to the sol, to obtain a seed-containing sol;   a step of drying the seed-containing sol to a moisture content of 15% by mass or less, crushing a residue, and then performing calcination at 550° C. or more and less than 1,200° C.; and   a step of performing firing at 1,200 to 1,500° C., wherein the polycrystalline alumina abrasive grains have an alumina content is 95.0% by mass or more, a silica content of 0.05 to 3.30% by mass, a grain size of 0.100 to 0.400 um, and a Vickers hardness of 21.00 or more.   
     
     
         2 . The method for producing the polycrystalline alumina abrasive grains according to  claim 1 , wherein in the step of obtaining the liquid mixture, an amount of the silica blended is 0.08 to 0.35 parts by mass with respect to 100 parts by mass of the solid content of the pseudo-boehmite. 
     
     
         3 . The method for producing the polycrystalline alumina abrasive grains according to  claim 1 , wherein the step of performing the calcination comprises a first calcination substep at 550° C. or more and less than 1,000° C. and a second calcination substep at 800° C. or more and less than 1,200° C. which is at a higher temperature than that of the first calcination substep. 
     
     
         4 . The method for producing the polycrystalline alumina abrasive grains according to  claim 1 , wherein the calcination and the firing are performed in a rotary kiln.